Method of forming integral outlets



Aug. 11., 1942.

.1. H. ROMANN E1- AL v2,292,799

METHOD OF FORMING INTEGRAL OUTLETS Filed out. 31, 1939 2 sheets-sheet 2 51 Ila-3L L INVENTOR JQ/zn Romana Gilberz A. Gaan?,

ATTORNEYS .lg-IAS the required dimensions.

UNITED STATES PATENT .OFFICE i METHOD OF FORMING INTEGRAL OUTLETS John H. Romann and Gilbert A. Gaum, Louisville, Ky., assgnors, by mesne assignments, to Tube Turns, Louisville, Ky.,

Kentucky a corporation of Application October 31, 1939, Serial No. 302,114

8 Claims.. (Cl. Ztl-157) The present invention relates to a method of and apparatus for shaping or swaging an outlet nozzle or neck on a metal blank as in the formation of a pipe T from tubular stock.

Difficulties have been encountered in prior efforts to shape such an outlet neck with the required wall thickness and the required length, and frequently it has been found necessary to sacrifice one of these desirable dimensions in order to obtain the other. Unless a more favorable redistribution of the available metal in the blank is eiected preliminary to the formation of the outlet' neck, and unless substantially all of the available metal is utilized in this formation,

the walls of the blank will be undesirably thinned out during the shaping operation in those regions of the neck where the stresses during use are heavy.

One object voi the present invention is to provide anew and improved method of shaping a metal blank to form an outlet neck thereon-of Another object is to provide a shaping method, in which the metal of the blank is displaced and redistributed prior to the neck drawing operation, to reinforce those regions of the blank forming the heavily stressed sections of the drawn neck.

Another object is to provide a shaping method, in which a minimum amount of metal is wasted in forming the necessary opening in the blank preliminary to the drawing of the outlet neck.v

Another object is to provide a shaping method forming an outlet neck'requiring a minimum' amount of trimming at its outer end to nish it, and resulting thereby in a minimum amount of metal wastage.

Fig. 4 is a. transverse section taken on line 4 4 of Fig. 3.

Figs. 5 .and 6 are views similar to those of Figs. 3 and 4 respectively, but showing the relative positions of the shaping apparatus and the blank at the end of the first step of the operation,

Fig. 'I is a view partly in longitudinal section and partly in elevation, showing the relative po'.

Another object is to provied a neck drawing method-'requiring thense of simple apparatus,

`minimum amount of heat, and a minimum amount of labor.

sitions of the shaping apparatus and the blank for the second step,

Fig. 8 is a section taken on line 8-8 of Fig. 7, Figs. 9 and 10 are views similar to those of Figs. 7 and 8 respectively, but showing the relative positions of the parts at the end of the second step, Fig. 11 is a longitudinal section showing the relative position of the blank and the shaping apparatus at the beginning of the third step,

Fig. 12 is av transverse section taken on line |2--I2 of Fig. 11, Figs. 13 and 14 are views similar to those oi Figs.` 1l and 12 respectively, with certain parts in elevation and showing the relative positions of' the various units at the conclusion of the third step,

Fig. 15 is a view partly in side elevation and partly in longitudinal section of the T tting formed by the shaping operation disclosed in outlet may be formed by the method embodying lVarious other objects and features of the invention will be apparent from the following particular description, and from an inspection of the accompanying drawings, in which- Fig. 1 is a longitudinal section of aesuitable tubular blank, which may be used for the forming of a T fitting by means ,ofia shaping `method and apparatus embodying the present invention'.

Fig. 2 -is a transverse section ofthe blank shown in Fig. 1, r

Fig. 3 is a longitudinal section showing the relative positions of the blank of Figs. 1 and 2 and the shaping apparatusV at the beginning of the shaping operation,

the present invention,

Fig. 20 is a transverse section ofthe tubular blank of Fig. 19,

Figs. 21 and 22 are viewsv similar to those of Figs. -19 and 20 respectively, but showing the blank at the conclusion of the first shaping step corresponding to that shown in Figs. 5 and 6,

Figs. 23 and 24 are views similar to those shown in Figs. 21 and 22, but'showing the article at the conclusion of the third shaping step cori responding to that shown in Figs. 13 and 14,

Figs. 25 to 30 inclusive are views in vertical section respectively, showing successive steps in the method ofl shaping a neck outlet on a at metal sheet blank in accordance with the pres- A ent invention, l

Fig.l31 is a fragmentary side elevation of a flat -metal sheet with a series of neck outlets, formed according to the method shown in Figs. 25 to 30, and after said outlets have been finished for welding,

Fig. 32 is a vertical section showing the first step in the method of forming a. neck outlet on a comparatively large curved shell or drum in accordance with the present invention, and

Fig. 33 is a fragmentary end view of the curved shell or drum of Fig. 32 at the conclusion of the shaping operation, and after the ends of its neck outlets have been trimmed for welding.

As shown in Figs. 1 and 2, the tubular blank I from which a pipe T is formed is desirably of eccentric cross-section, with the thickness of its wall varying from a minimum atthe lower side II to a maximum at its upper side I2, although as far as certain broader aspects of the invention are concerned, said blank may be of concentric cross-section.

If the tubular blank I0 is of such material that it can be worked cold, the heating thereof for shaping may be dispensed with. Otherwise the blank I0 is iirst'heated to an appropriate degrec.

The blank Il) either cold or preheated as described is placed over an anvil or swage block I3, with its thicker side I2 is position to receive the power of a hammer or swaging tool I4 as shown in Figs. 3 and 4. The anvil I3 is desrably provided with a comparatively small projection I5 adjacent to the thicker side I2 of the blank Il), and the hammer I4 has an indenting section I6, tapering towards a blunt or pointed end I1, ai'd may be of the power percussive type or of the pressure type.

After the blank and the various parts of thev shaping apparatus have been relatively arranged as shown ink Figs. 3 and 4, the hammer I4 is lowered as shown in Figs. 5 and 6, to indent the blank and force and displace the metal thereof radially outwardly from between said hammer and the anvil projection I5, thereby to form on the outer surface of said blank a curvedly crowned annular ridge I9 defining a depression 20. The metal of the blank I0 is thus displaced or swaged into those regions where it will be most useful in forming the neck Wall, with a strong junction between the neck and the main run or trunk of the ultimate T as will be made apparent hereinafter.

The swaging operation shownl in Figs. 5. and 6 will leave a thin layer 2| of metal at the baseof the depression 20 in the side wall of the blank I0. The thickness of this layer 2l depends on the extent of swaging pressure or force, and suiiicient pressure or force, may be exerted to break through the wall of the blank to form an opening at the base of the depression 20 during the shaping step" described. However, it gener` ally is not desirable to break entirely through the thin layer 2| at this stage of the process, for the reasons, among others, that such layer will serve as a cushion to protect the tools in the case of a percussion hammer blow, and also the layer improves the effectiveness of the drawing operations as hereinafter described.

After this swaging operation, the partially formed article is reheated if necessary and is inverted upon a die counter or block 23, with the previously swaged or ridged section of said blank extending substantially centrally over circular die hole 24 of said counter as shown in Figs. .7

and 8. A die rod 25 with apraised centrally disposed die section 26 is inserted into the partially shaped blank, with said die section disposed over the die hole 24, and said -blank and rod are relatively moved transversely towards each other by suitable power means into the position shown in Figs. 9 and 10, to force the dievsection 26 against the inner side of the blank opposite the ridged section thereof. This operation will deform the ridged section of the blank radially outwardly into the die hole 24 of the counter 23 as shown in Figs. 9 and 10, so that the mass of metal which is to form the wall of the outlet neck and the reinforced portion of its base is dished and shaped in preparation for the final neck drawing step.

After the completion of this second step, an aperture 30 is bored, punched or otherwise formed through the blank wall layer 2l. If desired, this additional aperture forming step may be eliminated, and the operation of breaking through the layer 2| eiected either by the steps shown in Figs. 5 and 6 as already described, or by having a die section 26 of sufficient height to break said layer in the step shown in Figs. 9 and 10. It is preferable not to form the aperture through layer 2l until after at least a part of the' dishing operation, such as shown in Figs. 9 and 10, is accomplished. If the aperture is formed before the dishing operation there is -a tendency for the metal around the aperture simply to ilex outwardly without drawing of the metal to the extent desired. On the other hand, the layer when present during the dishing operation, tends to resist such flexure with the result that a desirable preliminary drawing of the metal is secured during the dishing operation. A further advantage of leaving the thin layer until after accomplishment of at least part 'of the dishing operation, is that during Vsuch operation the layer is drawn and further thinned so that when the aperture is nally formed through the layer the amount of metal required to be removed is very small, resulting in minimum wastage and improved economy.

After the aperture 30 is formed, the blank' may be reheated if necessary and placed in operative position with respect to a neck drawing die as shown in Figs. 11 and 12. In the specific form shown, this drawing die comprises a die counter or block 3I, having a circular die opening 32' of a diameter corresponding to the outer diameter of the neck to be drawn. Extending into the blank IB is a die holder 33, provided with a transverse recess 34 to receive a male die 35 which is substantially of hemispherical shape with an upper hat side 36, and which has a maximum diameter equal to the internal diameter of the neck to be drawn. Passing substantially centrally through this male die 35 is a .pull or/draw rod 31, extending through the aperture30 of the blank I0, and secured to said male die' for downward movement therewith by any 'suitable means, as for instance a cotter pin 38,

by suitable power means, t e die 35 is forced against the lower previous ridged and dished section of the blank III, and through the die opening 32 of the counter 3' I to spread said secness as shown in Figs. 13 and 14. During this drawing operation, the upper half of the blank II is snugly conned in a semi-circular groove 4i of a block .42,while the lower half of said blank, except the portion thereof extending directly above the die opening 32, is snugly conned in a semi-circular groove 43 of the die block 3|.

As the result oi' the iinal drawing operation shown in Figs. 13 and 14, a neck outlet 40 will be formed having a substantial length, and having a substantial wall thickness, andthe junction 44 between said neck and the trunk of the article is of substantial thickness to eifectively withstand the heavy stresses to which said junction is usually subjected during use.

Although it is desirable to dish the ridged section of the blank by a separate operation preliminary to the final' drawing operation, as far as certain aspects of the invention are concerned, this dishing step and the drawing step can be performed by the drawing die in one continuous operation, especially if the blank isheated.

Any desired finishing operation may be performed to adapt the article for use in a welded or flanged piping system after the outer end of the neck has been trimmed. Assuming that the article is to be used in a welded piping system, chamfers 45 may be made to reduce the outer surfaces of the walls to the outside diameter of the pipes, and bevels 46a may be added in accordance with currentwelding practices, as shown in Figs. and 16.

The diameter of the neck outlet to be formed shown in Figs. 17 and 18, depending on the dimensions of lthe vrious dies used in the.shaping operation/'ff//y The/method ofthe present invention may be employed for the drawing of neck outlets from fiat/ metal sheets. For this purpose, a flat metal /f'sheet 50 as shown in Fig. 25 is placed on an anvil 5i underneath a hammer I4b similar to the hammer I4 of Figsf. 3 to 6, and said hammerv forced into said plate against said anvil to form a depression or indentation 20h enclosed by anannular ridge 19h as shown in Fig. 26. The ridged plate is then reversed and placed over the die opening -of a die block or counter 23h, and below a die member 53 with a substantially hemispherical conformation 54 as shown in Fig. 27. This die member 53 is lowered into contact with the ridged section of the plate as-shown in Fig. 28 to deform or dish said section downwardly into the die opening of the block 23D. The thin layer 2lb formed at the base o1'r the indentation 20h may be then removed` by boring or punching to form an aperture, or may be broken through by the indenting and deforming operations as already described with reference to the method of Figs. 1 to 14, and a drawfrod 56 of a drawing die 51 passed through said aperture. The die 51 has a substantially hemispherical conformation 60, and is power drawn through the opening of the die block 23h or of some similar block as shown in Figs. 29 and 30, to force the dished section of the sheet downwardly and radially outwardly against the innep periphery of the die opening of said block to form a neck outlet 6| as shown in Fig. 30.A Any number of these outlets may be formed on the plate as shown in Fig. 31, and the outer ends of these outlets may be trimmed, chamfered andbevelled for welding to a pipe or lit-5 40 ting connection.

I., The method ofthe present invention may be may be varied, and if a so-called reduced outlet is desired, the size of the necessary dies for the vin Figs. 1ste 1s.

shaping operation shown in Figs. 3 to 14 may be changed to form a T itting such as that shown in Figs. 17 and 18, with an outlet neck 46o`i substantially less 'diameter fthan that of the main run or trunk of the'iitting. ,f/

'I'he present method may be employed in the formationvof a lateral neck outlet in a comparatively long pipeJ as for, instance at one end thereof, to avo/id"the necessity of v rst' forming a separate j r iittingand then welding itto a pipe. To. form such a product, a longr'vpipe 41 such asv/that shown in Figs.vr 19 and 20' may be used ras the blank, and thecross-section thereof may be either eccentric as shown in Fig. 2, or may l hoof concentric cross-section as shown in Fig.

20. 'Ihibs'tubular blank is then subjected to a .preliminaiyswaging operation similar to that shown in Figs."3 to 6 to form an indentation 20a enclosed in a ridge 19a as shown in. Figs. 21 and 22. ,The ridged section of the blank 41 is then dished radially outwardly by an operation similar to that shown in Figs. 9 and 10, an

j vaperture formed at the base of the indentation and the dished section subjected to the neck drawing operation similar to that shown in Figs. 11 to 14, to form a neck outlet 48 as shown in Figs. 23 and 24. The outer end of this neck 48 may then be trimmed, chamfered and bevelled fory welding in the manner already described with reference to the final product shown The outlet neck 48 may be substantially of the same diameter as that of the main run or trunk of the pipe as shown in Figs. 23 and 24,

'or may be of reduced diameter similar to that so applied to the formation of neck outlets in fa'icurved wall of comparatively large diameter, as' for instance a boiler drum or shell. For that purpose, a drum 65 upon which the neck outlets are to be formed is seated on the curved surface' 66 of an anvil 61, and a 'hammer 14e similar to the hammer in the method of Figs. 1 to 30 forced downwardly to form an annular ridge,l I9c in said drum as shown in Fig. 32. The drum 65fand the anvil 61A may be moved relatively to form a series of these ridges according to the desired location of the outlet necks and the number thereof. The ridge sections can then be dished o `radially outwardly, and then drawn/Out into neck formations as in the methodsy previously described to form a series of neck outlets 10 on the drum as shown in Fig; 33. The diameter, length and thickness of the walls of these outlets may be varied by the use'of dies of proper size' and shape.

Although the method of the present invention has been shown as adapted to form cylindrical lar outline to form a rectangular ridge, and the drawing diewith its die counter may be of rectangular shaping conformation according to the desired shape of the neck outlet to be formed.

Also, if desired the neck outlet may be formed With its outer periphery tapering slightly towards its outer end by utilizing for the final drawing operation a die counter having a corresponding taper in itsdie opening.

As many changes could be made in the above construction, and many apparently widely different embodiments of this invention could be made without departing from the scope thereof, it is intended that all matter contained in the above description or shown in the accompanying drawings shall be interpreted as illustrative and not in a limiting sense.

Having thus described our invention, what we claim Vas new and desire to secure by Letters Patent is:

1. A method of forming a neck outlet in a metal blank, which includes the steps of subjecting an area of said blank, located substan-V tially centrally of the region from which the neck outlet is to be formed, to localized pressure directed generally normally to the plane of the blank in a manner to indent said area and cause displacement of metal generally radially from the intended area into a thickened ridge-like portion around said area, and thereafter "drawing the metal of saidndge-like portion into a neck outlet "extending laterally froml saidblank, and

of less wallthickness than said ridge-like portion.

2. The method of forming a neck outlet in a metal blank, which comprises indenting said blank substantially centrally of the region from which the neck outlet is to be formed,` and in a manner to cause displacement of metal generally radially from the indented area -into a thickened ridge-like portion around Il.said area,

and thereafter forming' an opening'through said blank at the base of the indentation and draJ .ug Y

the metal which` is around said opening, and including said ridge-like portion, into a'neck outlet extending laterally from the blank, andof lescwau thickness than said ridgeuk pognon.-

3. The method of forming a neck outlet'in a metal blank, which comprises indenting thblank in a manner to cause displacement of metal generally radially from the indented' area ntoa thickened ridge-like portion around-said yarea,

said indenting operation stoppingshort "of lcommember through said opening so as to draw the metal of said ridge-like portion into a neck outlet.

5. The method of forming a neck outlet in a metal blank, which comprises indenting said blank substantially centrally'of the region from which the neck outlet is to be formed, and in a manner to cause displacement of metal generally radially from the indented area into a thickened ridge-like portion around said area, said indenting operation stopping short of complete penetration of said blank, dishing said region of vthe blank outwardly in the direction in which the neck outlet is to extend, and forcing a die member through said blank so as to shape the metal of said dished region into a'neck outlet.

6. The method of forming a neck outlet in a metal blank, which comprises indenting said blank substantially centrally of the region from which the neck outlet is to be formed and in a vmanner to cause displacement of metal generally `radially from the indentation into a thickened ridge-like portionaround the indentation, thereafter dishing said region of thc-blank outwardly pletepenetration of the blank so as to `leave a relatively thin layer of metal at the ba'se of the indented area, and thereafter forming an opening in the base of the indented area and drawing and shaping'the metal of said ridge-like portion into a neck outlet extending laterally from the blank, said 'opening being formed after at least a part of thedrawing operation has been accomplished.

- 4. The'method of forming a neck outlet in' a metal blank, which comprises indenting said blank substantially centrally of the region from which the neck outlet is to be formed, to displace` metal generally radiallyfrom the indented area into a thickened -ridge-like portion extending varound the indentation and leaving-a relatively thin layer of metal at the base of the indentation, forming an opening through said thin layer at the base of the indentation, and .forcing a die vmetal blank, which comprises in in the direction in which the neck outlet is to, /exte/nd, to reduced the thickness of the ridge-like portion, forming an opening in the base of said indentation after at least a part of the dishing operation is accomplished, and forcing a die member through said opening to draw and shape the metal of said dished region into a neck outlet.

'7. The method of forming a neck outlet in a metal blank, which comprises pressing said blank by an indenting hammer having an outwardly tapering operating end to form an indentation and to displace the indented metal into .a thickened ridge-like portion extending around said indentation on one surface only of said blank, leaving a relatively thin layer of metal at the base of said indentation, thereafter forming an opening at the base of said indentationthrough said thin layer, and drawing the section of the blank around said opening in.a/

manner to shape themetal of said thickened porltion into the wall ofI aflateral neck outlet on the side of the blank on which saidgidge was formed.

8. The method of forming a `n ck outlet in a I nting said blank to displace the indented metal in o an endless ridge-like thickened portion on the outer surface, thereafter forming an opening at the base of the indentation centrally of said thickened portion, and forcing a die Y* y member /of maxio mum swaging cross-section equal t esired internal cross-section of the ne outlet W- ,wardly through said opening, wi 11e supporting said blank against a die blockhaying a die Opening corresponding in cross-sectiofn to the desired external cross-section of. the neckoutlet, thereby vto draw the metal of said thickened portion into said die opening and shape themetal of the ridge against the wall of said die opening to form a neck outlet.

Y JOHN H. ROMANN.

GILBERT A. GAUM. 

